A traveling-wire (TW) electroerosion apparatus in which at least one of wire guides which are disposed at opposite sides of the cutting zone has a plurality of guide elements with respective circular wire-receptive guide openings each of which is of a diameter substantially larger than a nominal diameter of the electrode wire and which are arranged to be mutually eccentric to make up a composite guide opening such that the diameter of an imaginary cylinder which can be inscribed therein is substantially equal to the nominal wire diameter. Preferably, the guide elements are arranged to be displaceable relative to one another and in their respective planes to change the eccentricity of these guide openings and thus to change the diameter of the imaginary cylinder.
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1. An apparatus for electroerosively cutting an electrically conductive workpiece with a continuous electrode wire, comprising:
means for axially transporting an electrode wire through a workpiece while defining a cutting zone therewith flushed with a cutting liquid medium; a pair of wire guide means disposed at opposite sides of the workpiece for providing a straight-line path for the traveling electrode wire therebetween; power supply means for electrically energizing said cutting zone to erosively remove material from the workpiece; and cutting feed means for relatively displacing the workpiece and the traveling electrode wire transversely along a programmed cutting path to advance the erosive material removal in the workpiece, wherein at least one of said wire guide means comprises: a plurality of guide elements arranged in the direction of travel of the electrode wire and having respective circular wire-receptive guide openings each of which has a diameter substantially greater than a nominal diameter of the electrode wire, said elements being disposed eccentrically with respect to one another to form a composite opening such that an imaginary cylinder which can be inscribed therein has a diameter which is substantially equal to the nominal diameter of the electrode wire. 3. An apparatus for electroerosively cutting an electrically conductive workpiece with a continuous electrode wire, comprising:
means for axially transporting an electrode wire through a workpiece while defining a cutting zone therewith flushed with a cutting liquid medium; a pair of wire guide means disposed at opposite sides of the workpiece for providing a straight-line path for the traveling electrode wire therebetween; power supply means for electrically energizing said cutting zone to erosively remove material from the workpiece; cutting feed means for relatively displacing the workpiece and traveling electrode wire transversely along a programmed cutting path to advance the erosive material removal in the workpiece, wherein at least one of said wire guide means comprises: a plurality of guide elements arranged in the direction of travel of the electrode wire and having respective circular wire-receptive guide openings each of which has a diameter substantially greater than a nominal diameter of the electrode wire, said elements being disposed eccentrically with respect to one another to form a composite opening such that an imaginary cylinder which can be inscribed therein has a diameter which is substantially equal to the nominal diameter of the electrode wire; and means associated with said at least one guide means for rotating at least one of said guide elements which among the others lies the closest to said workpiece, about an axis of rotation substantially coincident with the axis of said imaginary cylinder so as to maintain the axis of the opening of said closest guide element that it lies spaced from said axis of rotation in a direction which is parallel but opposite to the direction of a force acting on said traveling wire in said cutting zone and varying as a function of change in the course of the wire along said programmed cutting path.
4. An apparatus for electroerosively cutting an electrically conductive workpiece with a continuous electrode wire, comprising:
means for axially transporting an electrode wire through a workpiece while defining a cutting zone therewith flushed with a cutting liquid medium; a pair of wire guide means disposed at opposite sides of the workpiece for providing a straight-line path for the traveling electrode wire therebetween; power supply means for electrically energizing said cutting zone to erosively remove material from the workpiece; cutting feed means for relatively displacing the workpiece and the traveling electrode wire transversely along a programmed cutting path to advance the erosive material removal in the workpiece, wherein at least one of said wire guide means comprises: a plurality of guide elements arranged in the direction of travel of the electrode wire and having respective circular wire-receptive guide openings each of which has a diameter substantially greater than a nominal diameter of the electrode wire, said elements being disposed eccentrically with respect to one another to form a composite opening such that an imaginary cylinder which can be inscribed therein has a diameter which is substantially equal to the nominal diameter of the electrode wire, said guide elements being supported on support means displaceably substantially parallel to one another and means for displacing said guide elements to change eccentricity of one circular opening from another, thereby changing said diameter of said imaginary cylinder; and means associated with said at least one guide means for rotating at least one of said guide elements which among the others lies the closest to said workpiece, about an axis of rotation substantially coincident with the axis of said imaginary cylinder so as to maintain the axis of the opening of said closest guide element that it lies spaced from said axis of rotation in a direction which is parallel but opposite to the direction of a force acting on said traveling wire in said cutting zone and varying as a function of change in the course of the wire along said programmed cutting path.
2. The apparatus defined in
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The present invention relates to traveling-wire (TW) electroerosion and, more particularly, to an apparatus for electroerosively cutting an electrically conductive workpiece with a continuous wire electrode in which the accuracy of cutting is markedly improved.
The process of TW-electroerosion generally makes use of a continuous electrode wire which is typically circular in cross section and composed of, say, brass or copper, or brass- or copper-coated steel, the wire having a thickness or diameter generally ranging between 0.05 and 0.5 mm. The electrode wire is axially transported continuously from a wire supply to a wire takeup through a cutting region in which a workpiece is disposed. The cutting region is commonly defined between a pair of guide means which support and hold the wire while traveling through the workpiece. Wire traction and braking means allow the continuous wire to be tightly stretched and kept taut under a given tension and to be axially driven between the cutting guide members while traversing the workpiece, thus presenting a continuously renewed electrode surface juxtaposed in an electroerosive cutting relationship with the workpiece across a narrow gap or cutting zone. The cutting zone is flushed with a cutting liquid medium, e.g. water, and is electrically energized with a high current density electrical machining current which is passed between the electrode wire and the workpiece to erode the latter or erosively remove material therefrom.
The cutting process may be performed in any of various electroerosive machining modes. In electrical discharge machining (EDM), the cutting liquid is a dielectric liquid, e.g. deionized water, and the machining electric current is supplied in the form of a succession of electrical pulses. In electrochemical machining (ECM), the cutting medium is a liquid electrolyte, e.g. an aqueous electrolytic solution, and the machining current is a high-amperage continuous or pulsed current. In electrochemical-discharge machining (ECDM), the liquid medium has both electrolytic and dielectric natures and the machining current is preferably applied in the form of pulses which facilitate the production of electric discharges through the conductive liquid medium.
The workpiece may be disposed in a bath of the cutting liquid medium to immerse the cutting region therein. More typically, however, the cutting zone is disposed in the air or ambient environment. Advantageously, one or two nozzles of a conventional design are disposed at one or both sides of the workpiece to deliver the cutting liquid medium to the cutting region disposed in the air or immersed in the liquid medium. The cutting liquid medium is conveniently water as mentioned, which is deionized or ionized to a varying extent to serve as a desired electroerosive cutting medium.
To advance electroerosive material removal in the workpiece, the latter is typically displaced relative to the traveling wire and transverse thereto. This allows the travelling wire to advance translationally in the workpiece and consequently permits a narrow cutting slot to be progressively formed behind the advancing wire, the slot having a width substantially greater than the thickness of the wire. The continuous relative displacement along a precision-programmed path results in the formation of a desired contour corresponding thereto and defined by this cutting slot in the workpiece.
Higher cutting speed in the process described is ever an increasing demand in the industry and is desirable to achieve with due precision. The cutting speed, typically expressed in mm2 /min, is defined by the product of the workpiece thickness and the length of cut achieved per unit time along a given course and hence is, for a given workpiece thickness, dependent upon the rate of translational advance of the wire electrode that can be increased. The rate of advance is in turn limited by the rate of actual material removal dependent on the one hand upon the preset cutting parameters that govern, inter alia, the cutting accuracy and on the other hand upon the conditions in the cutting zone which may instantaneously vary. If the rate of advance happens to exceed the rate of actual material removal, the fine wire comes to break. The goal of higher cutting speed is, therefore, dependent on the extent to which optimum conditions in the cutting zone may be established and may be maintained stably against instantaneous changes.
In the interest of increasing the cutting accuracy in the TW-electroerosion process, it has been commonly recognized in the art that each of the wire guides disposed at opposide side of the workpiece have advantageously a so-called "die guide" structure with a small opening adapted to guidingly accept the traveling wire therein. A "die" opening is circular to conform with the wire which is circular in cross section as is common. Since the traveling wire stretched under tension remains confined within the opening, it does not come off fatally. When this structure is applied to the two guides, the centers of these openings establish the straight line for the axis of the wire when traveling through the cutting zone to coincide with. As can be seen, it is desirable that the clearance between the wire and the wall of the guide opening be minimized so that the wire axis may have suffer a minimal deviation from the straight line established by the centers of these openings. On the other hand, the guide opening must be large enough to allow the wire to be readily through. Thus, for example, for a wire of 0.2 mm diameter, a guide opening of a diameter as large as 0.21 mm has often been found to be inadequate.
The need for larger clearance also arises especially with respect to the "die" guide at the downstream side of the cutting zone. The wire passing out of the cutting zone has its surface substantially roughened and small pits and projections formed thereon as are typical in rough EDM operations. If such projections are large enough, the wire will be caught in the opening so that its length in the cutting zone becomes slack, causing a short-circuit with the workpiece. Then the wire will break.
As can readily be seen, the larger the clearance, greater the guiding inaccuracy and hence the inferior the machining accuracy. In an electroerosive cutting operation, there developes in the cutting zone a machining pressure (e.g. due to machining discharges) in the direction which is opposite to the cutting direction, thus tending to deflect the wire backwards. As a result, the wire in each of the guide openings will be forced to assume a deviated position with respect to the cutting direction, in spite of high tension applied to the wire to maintain it as straight as possible across the cutting zone. It can therefore be seen that there results a wire guiding inaccuracy and hence a machining inaccuracy which proportionally increases with an increase in the clearance or in the diameter of each guide opening.
Accordingly, the present invention seeks to provide a TW-electroerosion apparatus with a new, improved "die" guide assembly which can overcome prior-art problems as discussed above, thereby permitting a markedly enhanced accuracy of programmed cutting to be obtained.
In accordance with the present invention there is provided an apparatus for electroerosively cutting an electrically conductive workpiece with a continuous electrode wire, which comprises: means for axially transporting the electrode wire through the workpiece while defining a cutting zone therewith flushed with a cutting liquid medium; a pair of wire guide means disposed at opposite sides of the workpiece for providing a straight-line path for the traveling wire therebetween; power supply means for electrically energizing the said cutting zone to erosively remove material from the workpiece; and cutting feed means for relatively displacing the workpiece and the traveling electrode wire transversely along a programmed cutting path to advnce the erosive material removal in the workpiece, wherein at least one of the said wire guide means comprises: a plurality of guide elements arranged in the direction of travel of the electrode wire and having respective circular wire-receptive guide openings each of which has a diameter substantially greater than a nominal diameter of the electrode wire and which are arranged to be eccentric with one another to form a composite opening such that an imaginary cylinder which can be inscribed therein has a diameter which is substantially equal to the nominal diameter of the electrode wire.
Preferably, the guide elements are supported on support means displaceably substantially parallel to one another, there being provided means for displacing the guide elements to change eccentricity of one circular opening from another, thereby changing the diameter of the said imaginary cylinder.
Further preferably, there is also provided means associated with the said at least one guide means for rotating at least one of the guide elements which among the others lies the closest to the workpiece, about an axis of rotation substantially coincident with the axis of the said imaginary cylinder so as to maintain the axis of the opening of the said closest guide element spaced from the said axis of rotation in a direction of a force acting on the traveling wire in the cutting zone and varying as a function of change in the course of the wire along said programmed cutting path.
These and other features of the present invention as well as advantages thereof will become more readily apparent from a reading of the following description when taken with reference to the accompanying drawing in which:
FIG. 1 is a general schematic view of a typical TW electroerosion system including a pair of wire guide means;
FIG. 2 is a cross-sectional view diagrammatically illustrating an electrode wire which tends to fluctuate in position within a conventional "die" guide opening;
FIG. 3 is an elevational view partly in section diagrammatically illustrating a preferred form of the TW-EDM system incorporating the principles of the present invention;
FIG. 4 is an elevational view in section schematically illustrating one embodiment of the improved wire guide structure which is designed, in accordance with the present invention, to constitute the upper and/or guide assemblies in FIG. 3;
FIG. 5 is an enlarged view of a portion of the guide structure shown in FIG. 4;
FIG. 6 is a schematic view of three eccentric circular (cylindrical) guide openings projected on a common horizontal plane, also showing an immaginary cylinder, which can be inscribed in a composite cylinder they make;
FIG. 7 is an elevational view in section diagrammatically illustrating a modified form of the "die" guide structure according to the invention;
FIG. 8 is a diagrammatic cross-sectional view as taken along the line VIII and as viewed in the direction of arrows in FIG. 7;
FIG. 9 is a schematic view of three guide openings projected on a common horizontal plane and arranged to be coincident with one another;
FIG. 10 is a similar view of the guide openings when arranged to be eccentric with one another;
FIG. 11 is a perspective view diagrammatically illustrating a workpiece which is divided into two parts by TW-EDM according to the present invention;
FIG. 12 is an elevational view in section diagrammatically illustrating a guide assembly rotately carried by a nozzle housing for delivery of a cutting liquid medium according to a further embodiment of the present invention;
FIG. 13 is a diagrammatic cross-sectional view as taken along the line XIII--XIII as viewed in the direction of arrows in FIG. 12; and
FIG. 14 is a view similar to those shown in FIGS. 6 and 10, schematically illustrating how the guide element closest to the workpiece and hence the guide assembly is to be controlledly oriented as a function of a change in the course of the wire along a programmed cutting path, according to a further feature of the present invention.
Referring now to FIG. 1 there is schematically shown a traveling-wire electrical machining system for erosively cutting a workpiece 1 by means of an electrode wire 2 which is as thin as normally not greater than 0.5 mm. The wire 2 dispensed from a supply reel (not shown) is advanced over a guide roll 3, through a cutting zone 10 in the workpiece 1 and over guide rolls 4, and eventually is taken up onto a take-up means (not shown). The system is also commonly provided at opposite sides of the workpiece 1 with a pair of wire-positioning guide means 5 and 6 for establishing a desired straightline path along which the wire 2 is to axially travel under tension through the workpiece 1, thus providing a renewing electrode surface, in spacedly juxtaposed machining relationship therewith across a machining gap flushed with a machining fluid. An electroerosive machining current, typically in the form of a succession of electrical pulses, is passed through the machining gap between the wire 2 traveling to renew the electrode surface and the workpiece 1 while the latter is transversely advanced relative to the traveling wire 2 to advance electroerosion along a programmed path in the workpiece 1.
As each of the two wire-positoning guide means 5 and 6, it has been commonly recognized to be advantageous to employ a so-called "die guide" structure with a small opening 5a, 6a which as shown in FIG. 2, adapted to guidingly accept the traveling wire 2 therein. A "die" opening 5a, 6a is circular to conform with the wire 2 which is circular in cross section as is common. Since the traveling wire 2 stretched under tension across the guide rolls 3 and 4 remains confined within the opening 5a, 6a, it does not come off fatally. When this structure is applied to the two guide means 5 and 6, the centers of these openings 5a and 6a establish the straight line for the axis of the wire 2 when traveling through the cutting zone to coincide with . As can be seen, it is desirable that the clearance between the wire 2 and the wall of the opening 5a, 6a be minimized so that the wire axis may have suffer a minimal deviation from the straight line established by the centers of these openings. On the other hand, the opening 5a, 6a must be large enough to allow the wire 2 to be readily threaded. Thus, for example, for a wire 2 of 0.2 mm diameter, a guide opening of a diameter as large as 0.21 mm has often been found to be inadequate.
The further need for larger clearance arises especially with respect to the die guide 6 at the downstream side of the cutting zone. The wire 2 passed out of the cutting zone has its surface substantially roughened and small pits and projections formed thereon as are typical in rough EDM operations. If such projections are large enough, the wire 2 will be caught in the opening 6a so that its length in the cutting zone becomes slack, causing a short-circuit with the workpiece 1. Then the wire will break.
As can readily be seen, the larger the clearance, greater the guiding inaccuracy and hence the less the machining accuracy. In an electroerosive cutting operation, there develops in the cutting zone a machining pressure (e.g. due to machining discharges) in the direction which as shown by arrows 7 in FIG. 1 is opposite to the cutting direction indicated by arrow 8, tending to deflect the wire 2 backwards. As a result, the wire 2 in each of the guide openings 5a, 6a will, as shown in FIG. 2, be forced to assume a position 2 with respect to the cutting direction 7, in spite of high tension applied to the wire to maintain it as straight as possible across the cutting zone 10. It can therefore be seen that there results a wire guiding inaccuracy and hence a machining inaccuracy which is proportionally increased with an increase in the clearance or in the diameter of each guide opening 5a, 6a.
In FIG. 3 there is shown, in somewhat concrete form, a preferred TW-EDM arrangement to which the principles of the present invention may be applied. As in FIG. 1, the arrangement shown here employs a downward traveling movement of the electrode wire 2 through a cutting zone 10 in the workpiece 1. The guide rolls 3 and 4 are here mounted on upper and lower arms 11 and 12, respectively, which extend parallel to each other, horizontally from a column (not shown) standing upright on a base (not shown) in the conventional EDM design. The workpiece 1 is securely mounted on a worktable 13 movably mounted typically on the machine base and which in the conventional cross-feed arrangement is driven by a pair of motors 14 and 15 designed to move the workpiece 1 along an X- and a Y-axis, respectively, in a horizontal or X-Y plane. The motors 14 and 15 are designed to be energized with drive signals furnished from an NC (numerical control) unit 16 based on a set of instructions to move the workpiece 1 relative to the electrode wire 2 along a programmed cutting path in the X-Y plane. The electrode wire 2 is continuously dispensed from a wire supply (not shown) typically mounted on the machine column and, passing over the roll 3, through the workpiece 1 and over the lower roll 4, is collected onto a conventional takeup arrangement (not shown) which may extend over the lower arm 12 and the machine column.
Shown as disposed at opposite sides of the workpiece 1 between the rolls 3 and 4 are nozzle assemblies 17 and 18 comprising cylindrical base housings 19, 20 and cylindrical nozzles 21, 22 for delivering a cutting liquid medium into cutting zone 10 defined with the traveling wire 2 in the workpiece 1 while cooling the wire 2 and the workpiece 1. The nozzle 21 in the upper assembly 17 is designed to deliver the cutting liquid medium under a relatively low pressure and the nozzle 22 in the lower assembly 18 is designed to deliver the cutting liquid medium under a relatively high pressure. The two nozzles 21 and 22, upper and lower, are coaxial with the electrode wire 2 passing therethrough. The two nozzle assemblies 17 and 18 have similar structures and are arranged essentially coaxial with each other and thus have their axes substantially coincident with a desired path of travel of the electrode wire 2 through the workpiece 1.
The upper cylindrical nozzle 21 is slidably received in the cylindrical housing 19 through a lower opening 19a formed therein. The housing 19 is provided with a fluid inlet 19b communicating via a flexible hose 23 with a cutting liquid supply unit (not shown). The nozzle 21 is formed at its upper end with a circular flange or radial extension 21a slidably received in the housing 19. The flange 21a is resiliently supported on a helical spring 24 which is in turn seated on an annular inner adge formed at the lower end of the housing 19 to define the opening 19a. In this manner, the nozzle 21 is retained by the housing 19 against falling out due to gravity and also an inlet fluid pressure acting on the flange 21a within the housing 19.
Likewise, the lower cylindrical nozzle 22 is slidably received in the cylindrical housing 20 through an upper opening 20a formed therein. The housing 20 is provided with a fluid inlet 20b which communicates via flexible hose 25 with the cutting liquid supply unit. The nozzle 22 is formed at its lower end with a circular flange or radial extension 22a slidably received in the housing 20. The flange 22a cooperates with an annular inner edge formed at the upper end of the housing 20 to define the opening 20a so that the nozzle 22 is prevented from moving out of the housing 20 due to an inlet fluid pressure acting on the flange 22a in the housing. Furthermore, the housing 20 has a ring 26 attached at a suitable height on the inner wall thereof to hold the nozzle 22 against falling due to gravity below that height.
The housing 19 of the upper nozzle assembly 17 is here securely mounted on a carriage 27 which vertically depend from the horizontal arm 11. The carriage 27 is vertically movable relative to the arm 11 by means of a motor 28 carried thereon to adjust the vertical position of the upper nozzle assembly 17. The carriage 27 is also arranged to carry a wire-energizing pin 29 to locate it immediately above the housing 19, and a guide roll 29' adjacent the energizing pin 29 to hold it in steady electrical contact therewith the electrode wire 2 traveling from the upper roll 3 into the upper nozzle assembly 17. The housing 19 here has an upper opening 19c coaxially surrounding the wire 2 and the opening 19c is of a diameter sufficient to allow a portion of the introduced cutting liquid medium in the housing 19 to flow out therethrough to cool the energizing pin 29 and the electrically energized wire 2 prior to entry into the upper nozzle assembly 17.
The energizing pin 29 is electrically connected to one terminal of an EDM power supply (not shown) while the workpiece 1 is electrically connected to the other terminal thereof to pass an erosion current between the workpiece 1 and the traveling wire 2 in the cutting zone. That one terminal of the power supply may also be electrically connected to the conducting roller 4 to apply the erosion current to the traveling wire 2 through a portion thereof leaving the lower nozzle assembly 18 through a lower opening 20c formed in the housing 20. Thus, a substantial traveling length of the wire 2 which is electrically energized is held thoroughly in contact with the cutting liquid medium as coolant while moving from the energizing pin 29 through the upper nozzle assembly 17, the workpiece 1 and the lower nozzle assembly 18. The conducting guide roll 4 is rotationally mounted on a block 31 which is securely mounted on the lower horizontal arm 12.
When the housing 19, fixed in position, of the upper nozzle assembly 17 is supplied with the pressurized cutting liquid medium from the fluid supply unit, the "floating" nozzle 21 is moved down with the fluid pressure acting on the flange portion 21a and is projected from the housing 19 while directing the cutting liquid medium to flow, coaxially with the electrode wire 2, out of the nozzle opening 21b partly downwards into the workpiece 1 as shown by arrow 32 and partly latrally radially through the small annular interstice defined with the upper surface of the workpiece 1. Likewise the nozzle 22 in the lower nozzle assembly 18 is "floated". When the housing 20 is supplied with the pressurized cutting liquid medium from the supply unit, the nozzle 22 supported on the stop ring 26 is moved up with the fluid pressure acting on the flange portion 22a and is projected from the housing 20 while guiding the cutting liquid medium to flow, coaxially with the electrode wire 2, out of the nozzle opening 22b partly upwards into the workpiece 1 as shown by arrows 33 and partly laterally radially through the small annular interstice defined with the lower surface of the workpiece 1.
The workpiece 1 has a cutting slot S electroerosively formed therein behind the electrode wire 2 as the wire is effectively moved translationally, here from right to left, in and relative to the workpiece 1 in the course of cutting feed displacement of the latter by means of the motors 14 and 15 and the feed controller 16. Electroerosion current is passed between the electrode wire 2 traveling through the workpiece 1 and a portion of the workpiece adjacent thereto across a narrow erosion gap flushed with the cutting liquid medium. A cutting front, thus progressively formed in the workpiece 1, has a semi-cylindrical surface equally spaced from the electrode wire 2 across the erosion gap spacing and is designated by reference CF. The cutting front CF and hence the cutting slot S having a narrow width, being equal to the diameter of the electrode wire 2 plus the twice the erosion gap spacing. Since the erosion gap spacing is constant or held to be always constant by relative displacement between the workpiece 1 and the wire electrode 2 effected under programmed drive commands of the feed controller 16, the machined accuracy of the cutting front CF, i.e. the accuracy of actual cutting in the workpiece 1, is a direct function of the positioning accuracy of the electrode wire 2 in the cutting zone 10.
Shown as mounted in the housings 19 and 20, respectively, are upper and lower wire-positioning guide assemblies 50 and 60 which correspond to those 5 and 6 shown in FIG. 1. The upper guide assembly 50 comprises a downwardly convergent body 51 which carries at its lower end a "die" or annular guide 52 for slidably guiding the electrode wire 2 traveling into the workpiece 1. The tubular body 51, which thus constitutes a guide holder, is here formed with apertures 51a so that the cutting liquid medium introduced through the inlet 19b may be partly diverted to flow in contact with the electrode wire 2 in the body 51 and to flow out through the apertures 51a towards the nozzle opening 21b. Likewise, the lower guide assembly 60 comprises an upwardly convergent tubular body 61 which carries at its upper and a "die" or annular guide 62 for slidably guiding the electrode wire 2 traveling from the workpiece 1. The tubular body 61, which thus constitutes a guide holder, is, here again, formed with apertures 61a to enable a portion of the cutting liquid medium introduced through the inlet 20b to be diverted to flow in contact with the electrode wire 2 moving in the holder 61 and to flow out through the apertures 61a towards the nozzle opening 22b. In the embodiment illustrated in FIG. 3, the guide holders 51 and 61 are securely fixed to the housings 19 and 20, respectively.
In the arrangement shown and described, one or each of the "die" guides 52 and 62 has an improved structure to be described in accordance with the present invention to assure a highly accurately positioning of the electrode wire 2 traveling through the cutting zone 10.
In FIGS. 4 and 5, one embodiment of the improved structure is illustrated. An improved "die" guide 70 shown comprises three stacked guide elements 71, 72 and 73 having their respective circular openings 71a, 72a and 73a which are arranged to be eccentric with one another so as to collectively make a composite opening such that an imaginary cylinder which can be inscribed therein has a diameter substantially equal to a nominal diameter of the electrode wire 2. Each of the guide elements 71, 72 and 73 may be integrally formed of a hard, friction-resistant material, or alternatively may have a ring fitted therein, which is formed of such a material, to provide the wire-guiding opening 71a, 72a, 73a. The hard, friction-resistant material is preferably diamond. In the embodiment shown, the three openings 71a, 72a and 73a are cylinders of an equal diameter whose eccentric centers or axes are shown at A1, A2 and A3 in FIG. 6 as arranged with an equal eccentricity. These eccentric cylinders make a composite opening collectively defined by the cylindrical walls shown by solid lines 71a, 72a and 73a in FIGS. 5 and 6. Also seen in FIGS. 5 and 6, an imaginary cylinder shown by phantom lines 74 can be inscribed in the composite openings 71a, 72a, 73a. Each of the separate openings 71a, 72a and 73a can be and are dimensioned substantially larger in cross section than the electrode wire 2 but can be and are arranged so that the imaginary cylinder 74 with its center or axis O equally spaced from the centers or axes A1, A2 and A3 for the openings 71a, 72a and 73a has a diameter substantially equal to a nominal diameter of the electrode wire 2. Preferably, the center or axis O of the imaginary cylinder lies coincident with the axis of the guide holder 51, 61 which is in turn coaxial with the housing 19, 20 and the nozzle 21, 22. Thus, if each of the separate openings 71a, 72a and 73a are so dimensioned and arranged, the electrode wire 2 can be threaded and passed through without any difficulty and yet can be held to maintain its axis substantially coincident with a true axis O and thus to maintain its accurate positioning relative to the workpiece 1 in the cutting zone 10.
For example, the openings 71a, 72a and 73a may each have a diameter as large as 0.22 mm for a nominal wire diameter of 0.20 mm and may be arranged to provide an imaginary cylinder with a diameter of 0.20 mm so that the wire has in effect no clearance therewith. As shown in FIG. 5 it is desirable, for ease of wire threading, that the guide element 71 at the wire inlet side have a conical inlet surface 71b tapered convergently towards and adjoining with the guide opening 71a and the guide element 73 at the wire outlet side have conical outlet surface 73b tapered divergently from the guide opening 73a. In addition, the intermediate guide element 72 and the outlet guide element 73 should desirably have their inlet opening edges rounded as shown at 72b and 73c so that the wire 2 can be smoothly moved from one guide element to another.
The improved guide structure 70 described is particularly advantageous for the "die" guide 62 at the downstream side of the workpiece 1 which entails more serious problems than the "die" guide 52 at the upstream side as mentioned previously. Where the structure is employed to make up at least the "die" guide 52 at the upstream side it should be noted that an imaginary cylinder 74 may be selected having a diameter even slightly less than the diameter of the electrode 2. In this case it has been found desirable that a powerful takeup mechanism at the lower guide roll 4 or downstream thereof be employed. Then the wire 2 when passed through the composite opening 71a, 72a and 73c of such narrow effective diameter is plastically worked prior to entry into the cutting zone, thereby to increase its straightness, hence further enhancing its positioning accuracy in the cutting zone 10. It should also be noted that while in FIGS. 4 and 5 the guide elements 71, 72 and 73 are shown as arranged in contact with one another, this is not imperative. Thus, they may be vertically spaced from one another with a small spacing, say, not greater than 1 mm and made by any suitable non-guiding spacer or spacers.
It is desirable that the diameter of the imaginary cylinder 74 be variably adjusted. In the modified arrangement of FIGS. 7 and 8, the guide elements 71, 72 and 73 having their respective guide openings 71a, 72a and 73a are movable, with respect to the guide holder 19, 20, along horizontal axes which are transverse to one another and as viewed from top or down are mutually spaced apart with an angle of 120°. Each of the guide elements 71, 72 and 73 is here in the form of a square plate. Here again they may be integrally formed of a hard, friction-resistant material, or alternatively may each have a ring fitted therein, which is formed of such a material (e.g. diamond or sapphire), to provide the respective openings 71a, 72a and 73a. The guide elements 71, 72 and 73 are slidably retained in guideways 75a, 76a and 77a formed in disk plates 75, 76 and 77, respectively, which are on the one hand bolted to a cylindrical casing 91 and on the other hand secured to the casing 91 by means of three horizontal bars 78, 79 and 80. The cylindrical casing 91 is preferably a hollow ring arranged to coaxially surround the guide holder 51, 61 and secured thereto, coaxially within the nozzle housing 19, 20. Alternatively, the casing 91 may be constituted by the cylindrical housing 19, 20 itself. A spring 81 is inserted in each guideway 75a, 76a, 77a in engagement with one side surface of each guide element 71, 72, 73 to resiliently hold it therein. The other side surface of each guide element 71, 72, 73 is in engagement with the free end surface of spindle 82, 83, 84 in its guideway 75a, 76a, 77a, the spindle being the spindle portion of a screw having a head 82a, 83a disposed outside of the casing 91. The screw is threaded through a nut 85, 86, 87 in mesh therewith, which passes through the wall of the casing 91 and is secured thereto. Each spindle 82, 83, 84 has a ring stopper 88, 89, 90 mounted thereon which is engageable with the nut 85 to hold the position of each guide element 71, 72, 73 in the guideway 75a, 76a, 77a within a fixed limit.
Here again, the guide openings 71a, 72a and 73a are advantageously of an equal diameter R1 which is much or substantially greater than the diameter of the electrode wire 2. Likewise, the guide elements 71, 72 and 73 and all mentioned parts respectively associately therewith are advantageously dimensioned to be precisely equal in size, respectively. Thus, by turning the screw heads 82a, 83a and 84a to advance the guide elements 71, 72 and 73 with the spindles 82, 83 and 84 to a given extent against the urging pressures of the springs 81, it is possible to position the guide openings 71a, 72a and 73a all in alignment as shown in FIG. 9 so that their respective axes A1, A2 and A3 are coincident with one another at O and with the axis of the housing 19, 20 and hence that of the nozzle 21, 22. Then, the electrode wire 2 can conveniently be threaded through the guide assembly 50, 60 since the largest diameter R1 is established therein.
The screw heads 82a, 83a and 84a are turned reverse to retract the spindles 82, 83 and 84 and to allow the guide elements 71, 72 and 73 under the urging pressures of the springs 81 to move backwards. The parallel guide openings 71a, 72a and 73c are moved eccentrically above the axis O to reduce the diameter of the imaginary cylinder inscribed in the composite cylinder they make. The axis of the imaginary cylinder remain unchanged and coincident with the original axis as far as the openings 71a, 72a and 73a are shifted with equal eccentricity or their axes A1, A2 and A3 are equally spaced apart or spaced from the original axis O with equal distance as shown in FIG. 10. The diameter R1 of the effective opening or imaginary cylinder is determined in a direct function of the eccentricity or the shift of the axis A1, A2, A3 from the center O. A particular diameter R2 can be set up depending upon a particular mode of TW-EDM operation. If a rough machining operation is to be performed, the diameter R2 is set to be relatively large. For a finish machining operation using a wire electrode of the same diameter, a minimum of the effective wire-guide opening diameter R2 may be employed. Such a change is particularly important for the guide assembly 60 at the downstream side of the workpiece 1.
An SKD (Japanese Industrial Standard) steel plate workpiece 1 having a thickness t of 10 mm is machined to obtain a cubic block 1' as a desired product as shown in FIG. 11. The block 1' is initially cut out from the workipiece 1 using a rough TW-EDM operation with machining pulses having a peak current of 210 amperes and a discharge pulse duration of 0.6 microsecond and at a cutting speed of 210 mm2 /min. In this operation, the upper guide assembly 50 has an effective guide opening R2 (as mentioned) of 0.206 mm and the lower guide assembly 60 has R2 of 0.210 mm. The rough-cut block 1' is then finish-cut upon changing R2 of the upper guide assembly 50 to 0.202 mm and R2 of the lower guide assembly 60 to 0.203 mm and using machining pulses having a peak current of 150 amperes and a discharge pulse duration of 0.3 microsecond. The finishing operation proceeds at a cutting rate of 100 mm2 /minute. The block 1' so machined is measured and it is found that the lengths of the block 1 is the X-direction are 10.021 mm, 10.021 mm and 10.022 mm at its upper, middle and lower regions, respectively and lengths of the block 1' in the Y-direction are 10.020 mm, 10.020 mm and 10.021 mm at the upper, middle and lower regions, respectively. Thus, a machining accurary of ±1.5 micrometer is obtained. The machined block 1' has a surface roughness of 1.2 μmRmax.
FIGS. 12 and 13 show a further improvement of the novel wire guiding system according to the invention. The system is shown for illustrative purposes with respect to the upper guide assembly 50 but is equally applicable for the lower guide assembly 60. The assembly 50 shown comprises a perforated tubular guide holder 51 which is coaxial with the nozzle housing 19. The common axis is here again denoted as O. The guide holder 19 carries at its lower end a guide structure 70 shown in and described in connection with FIGS. 4-6, or 70' shown in and described in connection with FIGS. 7-10, in which only the one guide element 73 with the guide opening 73a which lies the closest to the workpiece 1 is shown as significant for a description to be made of this embodiment.
As is seen, the axis A3 of the circular guide opening 73 is shifted by a distance or eccentricity a from the axis O of the mentioned imaginary cylinder, that is the desired axial position of the electrode wire 2 being guided. This embodiment is designed to maintain the axis A3 spaced from the system axis O in a direction parallel but opposite to the direction of a force acting on the wire 2 in the cutting zone, irrespective of changes in the course of the wire 2 along a programmed cutting path in the workpiece 1.
In this embodiment, therefore, the tubular guide holder 51 carrying the multiple-opening guide assembly 70, 70' is mounted rotatably about its axis O on the nozzle housing 19 previously described. In the illustrated arrangement, the guide holder 51 is journaled on a pair of bearings 93, 94 secured to the housing 19 as shown. The guide holder 19 has, near its upper and outside of the housing 19, has a geared ring 95 secured thereto, which is in mesh with the geared onput shaft 96a of the motor 96. The upper bearing 93 below the geared ring 85 is seated on the bored top of the housing 19 while the lower bearing 94 is supported by four bars 97 secured to the inner wall of the housing 19. The motor 96 is designed to be driven in response to signals from the NC unit 16 (FIG. 3) to rotate the guide holder 51 so that the eccentric guide opening 73a is oriented in a particular direction.
Assume in FIG. 14 that the wire 2 in the cutting zone 10 is effectively advancing translationally in the direction of arrow 8 to advance cutting along a programmed path. As mentioned previously, a machining pressure is created in the cutting zone to force back the wire 2, thus in the direction, as shown by arrow 7, opposite to the cutting direction 8. In spite of this force, it is desirable that the wire 2 when passing through the guide opening 73a have its axis precisely coincident with the established system axis O so that the wire 2 makes along its rear side C contact with the wall of the opening 73a. This requires that the axis A3 of the opening 73a lies spaced from the system center O in a direction parallel but opposite to the direction of the force 7. When the cutting direction or course of cutting is changed to lie 8' along the programmed path, the force 7' is correspondingly changed. This change is detected in the NC unit 16 which thus transmits a change of course signal adapted to drive the motor 96 until the axis of the guide opening 73a is shifted to the commanded position A3' which again lies spaced from the center O in the direction parallel but opposite to the force 7' acting on the wire 2 in the cutting zone. In this manner, the axis A3 of the wire-guide opening 73a of the guide element which is the closest among others to the workpiece can remain spaced from the present center axis O in the direction such that the wire 2 is backed up in the opening 73a to counter-balance the force acting thereon in the cutting zone 10.
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| Jun 25 1984 | Inoue-Japax Research Incorporated | (assignment on the face of the patent) | / |
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